Dual Primary Winding Ignition Coil for High Energy Spark

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Solution Overview

Problem

Existing vehicular ignition systems face challenges in retrofitting to increase spark energy without damaging existing coil drivers and ECUs, as they are unable to handle the increased currents required for enhanced spark characteristics.

Innovation Solution

The system employs a dual primary winding ignition coil configuration, where a second current is supplied to a secondary primary winding after sensing the first current in the first primary winding, allowing for optimized spark characteristics without overloading existing controllers or drivers, and enabling operation with a variety of coils.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If users replace older coils with newer coils having lower inductances to increase current and stored energy, then spark energy is improved, but existing coil drivers and ECUs are damaged or destroyed by the increased currents

Engineering Contradiction:

Improvespark energyVSAvoidcoil driver and ECU reliability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The primary winding is divided into two separate primary windings (first primary winding and second primary winding), each capable of being independently driven. This segmentation allows the system to distribute the current load across multiple windings, enabling higher total current and energy storage without overloading existing coil drivers and ECUs, thus resolving the contradiction between improved spark energy and component reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple primary windings into a single ignition coil assembly, where the magnetic fields from both windings are merged and additive. This merging allows the system to achieve higher total current and stored energy (improving spark energy) while each individual winding operates within safe current limits for existing drivers and ECUs (maintaining reliability)

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If existing systems are retrofitted to provide increased spark energy, then spark characteristics are enhanced, but existing system components are damaged or destroyed

Engineering Contradiction:

Improvespark energy outputVSAvoiddamage to existing components

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

By segmenting the primary winding into two separate windings that can be independently controlled, the system can retrofitted to deliver increased spark energy through combined current from both windings, while each individual winding operates within the safe current handling capacity of existing components, preventing damage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the electrical parameters of the ignition system by introducing a second primary winding with its own current path. This allows the system to increase total current and stored energy for enhanced spark output while maintaining individual winding currents at levels that existing components can safely handle, thus improving productivity without causing harmful effects

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If multiple primary windings are used to increase current and stored energy, then spark characteristics are optimized, but system complexity increases

Engineering Contradiction:

Improvestored energy in magnetic fieldVSAvoidignition coil structure

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent merges multiple primary windings into a single integrated ignition coil assembly with a common magnetic core and shared secondary winding. This merging approach allows the system to increase stored energy through multiple current paths while maintaining a compact, unified structure that minimizes the increase in device complexity compared to using completely separate coil assemblies

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach allows for enhanced spark energy, duration, or current without damaging existing system components, while maintaining compatibility with various ignition coils, ensuring safe operation and transparent differences in operating characteristics to existing controllers and drivers.

Implementation Method 1

electrical current flows through a primary winding of an ignition coil and this current flow induces energy to be stored in a magnetic field associated with the coil

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The stored energy of the coil is released when the primary winding current is suddenly turned off and the released energy flows from the magnetic field as a secondary current in a secondary winding of the ignition coil

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS7836869B2Multiple primary coil ignition system and method

Publication Date: 2010.11.23 MSD LLC

AI summary

An original coil having a single primary winding is replaced with a replacement ignition coil having a first primary winding and a second primary winding. The replacement coil is coupled to the existing controller of the ignition system and to a spark plug. The controller is operated within predefined operating limits so as to optimize at least one predetermined ignition spark characteristic of the spark plug.